Building unit



A. w. REMMEL ETAL BUILDING UNIT June 9, 1942.

Filed Oct. 15 1939 2 Sheets-Sheet l fg g -14 ATTORNEY Patented June 9, 1 942? UNITE STATES OFFICE BUILDING UNIT Application October 13, 1939, Serial No. 299,230

4 Claims.

This invention relates to improvements in panels or structural units for housing construction.

One of the objects is to provide an improved structural unit adapted for connection with-similar units to quickly form a building frame in which steel support members are encased within the confines of a layer of insulation.

Another object is to provide an improved structural unit having steel support members and. wood nailing supports adapted to hold a plaster finish in a manner to prevent the steel members from sweating through and showing up in the finish.

Another object is to provide an improved structural unit adapted to resist the spread of fire and check air circulation within the walls formed by said unit as assembled in place.

Another object is to provide an improved structural unit which is adapted to be preformed, and is so constructed and arranged asto permit a plurality of them to be readily associated in a desired type of structure.

The foregoing objects are accomplished by forming the unit or panel of steel studs, by providing wood cross nailers or girts at spaced intervals between said studs, by securing to said girts on one side thereof a layer of insulation comprising wood fiber insulation board and plywood spaced by furring strips to form a dead-air space between the insulation board and plywood, and by projecting the inner edge of the girts beyond the sides of the steel studs so that gypsum board or other plaster-holding lath may be fastened thereto spaced from the studs. The panel so constructed when keyed to other similarly constructed panels forms a building" frame in which:steel support members are positioned Wholly within the layer of insulation and are thereby protected by being maintained at inside or room temperature; dead-air spaces between horizontal girts prevent the spread of fire through the walls; wood girts form nailing facilities for plaster base or other interior finish and maintain the plaster or other finish spaced from the steel support members, thereby preventing the sweating through and' showing up of the steel studs in 'the interior finish; dead-air spaces between the plywood and insulation board increase the effective insulation.

The novel features, which-are considered characteristic of the invention, are set forth with particularity in the appended claims- The invention itself, however, both as toits organization and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of a specific embodiment when read in connection with the accompanying drawings, in which:

Figure 1 is a' fragmentary perspective view showing how brick or wood siding is applied to a frame constructed of the improved exterior wall panels forming part of the invention;

Figure 2 is a fragmentary View in elevation showing the inside or plaster side of the improved exterior wall 'panel;

Figure 3 is a sectional view taken on line 3-3 of Figure 2;

Figure 4 is a sectional view taken on line i4 of Figure 3.

Figure 5 is an enlarged fragmentary perspec-- tive view showing an interior partition panel and the method of securing a sound-deadening quilt therein.

Figure 6 is an enlarged fragmentary sectional View of the interior panel shown in Figure 5.

Figure 7 is a top plan view of an improved floor and ceiling panel;

Figure 8 is a sectional view taken on line 8-8 of Figure '7.

Figure 9 is a sectional view taken On line 9-9 of Figure 8. v

Figure 10 is a fragmentary perspective view of the saddle bracket for connecting together two exterior wall panels and two ceiling floor panels; and

Figure 11 is a fragmentary perspective View showing the manner of connecting the floor panels to the foundation, and of seeuringthe exterior wall panels to the floor panels.

Referring in greater detail to the drawing generally the exterior wall panel designated EP comprises two steel studs I0| I.

able that the studs be fabricated gauge copper bearing pressed steelcliannel' 3', wide with 1%" flanges approximately 8"-l0 in height where an eight foot ceiling is desired. The studs l0 and H are spaced approximately 40" apart, with the flanges on one extending -toward the flanges on the other. Wood cross nailers or girts l2 extend between thestuds'at vertical spacings of approx'im'ately "16" center to center. The wood cross nailers are preferably 1 thick by 3% in width. The corners of the nailers are notched, as 'at' l3 and l4; to 'permit the ends to fit between the studs II and be secured thereto by nails driven through holes in the flanges of" the studs;

It is prefer- Notches [3 are of greater depth than-notches" l4 of 15 U. S.

fian-gesof the so that the inner edge I5 of the girts 12 projects beyond the inner flanges of the studs l and II, as is clearly illustrated in Figure 3. The notches M are approximately the same depth as the thickness of the flanges of the studs 18 and H, so that the outer edges of the girts l2 are approximately flush with the outer surfaces of the outer flanges. The cross nailers are provided with dado cuts l6 for the installation of electric wiring, plumbing, etc. At the tops of the studs [0 and l I there are provided connection brackets l1 and I8. The flanges at the top ends of the studs are compressed amount to permit the brackets 11 and I8 to fit thereon with the flanges of said brackets overlapping and welded to the flanges on the studs, as is indicated in Figure 5. The brackets I1 and I8 are provided with suitable apertures for connection with the saddle bracket illustrated in Figure 10. The lower ends of the channels it! and II have welded thereto bearing plates l9 and 20 (20 not being shown). To the outer edges of the cross nailers l2, coextensive with the area defined by the studs 50 and l E, there is secured a sheet of wood fiber insulation board 2|. Overlying the wood insulation board 2| and spaced therefrom by furring strips, is a threeply water-resistant, glued, fir ply-wood covering 22. The wood furring strips 23 extend around the entire border of the panel. There are additional vertical furring strips 2-; vertically positioned and spaced approximately at the 13" centers between the studs 18 and H. The insulation board 2|, plywood covering 22, and furring strips 23 and 24 are all nailed directly to the wood cross nailers 12. In order to provide for a good joint between two of the exterior wall panels constructed as above, the side edges of the plywood covering 22 are recessed from the edges of the furring strips 23, as indicated at 25.. As is clearly shown in Figure 10, a batten strip 25 is fitted between the recessed edges of adjacent coverings 22 when the panels are assembled in position. As shown in Figure 2, the lower portion of the flanges of the studs l0 and II have spaced apertures 21-28 (28 not shown) for securing the exterior wall panel EP to a floor panel, in the manner indicated in Figure 11. As also shown in Figures 2 and 11, the exterior wall panel EP is provided with an additional cross nailer installed near the bottom of the panel to serve as a backing for baseboards, or other similar type of interior finishes.

Similarly to the exterior panel, the interior wall panel 1P likewise comprises two steel studs having extending between them cross nailers. The studs 29 of the interior wall panel IP are approximately 8-l/2" high for an eight foot ceiling. The studs are preferably of the same copper bearing steel press channels as the studs of the exterior wall panel, the only differences being that the bearing bracket 38, welded to the bottom of the studs 29 (as clearly shown in Figures and 6), has portions extending outwardly from each flange of the stud 29 provided with apertures permitting the interior panel I? to be nailed to sub-flooring and the like. The cross nailers 31 of the interior wall panel are preferably 3 in width, and the notches 32 are each of identical depth so that both edges of the cross nailers 3| extend beyond the outer surfaces of the flanges of the stud 29..

As illustrated in Figures 5 and 6, it is sometimes preferable to make the interior panel a sound-deadening panel. To accomplish this the cross nailers 3| are made in two pieces, which pieces have inserted between them, before fitting into the studs, a sound-deadening quilt 33. The sound-deadening quilt 33 fits closely up against the web of the studs 29, and extends completely from top to bottom of the interior panel.

The ceiling floor panel CF comprises a welded steel frame made up of end channels 34-35, and side channels 38-31. The end channels are preferably 40 long, while the side channels are inwardly a sufficient preferably of any desired length up to approximately 16 All channels. are preferably fabricated of 15 U. S. gauge copper bearing steel 8" in width with 1 flanges. The flanges of the end channels 3 1-35 overlap the flanges of the side channels 36 and 31, and are welded in substantially the same manner as the brackets l3 are secured to the studs l0 and H, as shown in Figure 5. Extending between the side channels 36 and 31 are 1%" by 2% wood cross nailers 38 forming a bearing support for flooring. Directly below the cross nailers 33, as viewed in Figure 7, are 1 by 1%" wood cross nailers 39. The cross nailers 39 are also spaced at approximately 16 centers to provide the support for the interior ceiling finish. Both sets of wood cross nailers 38 and 39 have the outer edges thereof notched, as indicated at 4!, so that the outer edges thereof lie substantially flush with the outer surfaces of the flanges of the channels 36 and 31. At the ends of the wood cross nailers 38 and 39, and surrounding the inner edges thereof, are provided U-shaped brackets M. The brackets 4| are screwed to the cross nailers, and are welded to the side channels 36 and 31, respectively, after the cross nailers are placed in their proper positions. The end channels 33 and 35 are provided with apertures 42 providing passage-ways for electric wiring, plumbing, heating ducts, etc.

In constructing a building framework using the floor and ceiling panels CF, exterior wall panels EP, and interior wall panels IF, the general procedure is to first place on the top of the foundation walls an insulation strip 43. The floor panels CF are then placed on top of the insulation strip and are anchored by anchor plates 44, which are secured to the foundation by means of bolts embedded in the concrete at the time of its construction. All floor panels CF are keyed together using a locking key and taper pin arrangement of the type shown in Figure 10. It is then preferable to lay wood sub-flooring diagonally over the entire floor area and to nail it to each floor nailers 38 of the various floor panels comprising the desired framework.

The next step is to place at one corner of the building framework, and at the narrow end of a floor panel CF, an exterior wall panel EP.

, The exterior wall panel EP rests on the insulation strip 13 and is secured to the floor panel CF by bolts and nuts extending therebetween; the panels being spaced by lock nuts, as illustrated at 45 in Figure 11.

The following step is to secure a corner post 0? to another exterior wall panel EP. (The corner posts are indicated generally in Figure 1 and are more particularly described in the application of Jesse H. Bates and Thor 1-1. Hansen, Serial No. 166,259, filed September 29, 1937, Patent No. 2,181,169, Nov. 28, 1939, for Prefabricated houses) This exterior wall panel and corner post are erected on the other side of the corner adjacent to the exterior wall panel first erected. The corner post CP is keyed to the first. panel erected, and thesecond exterior wall panel is secured to the floor panel in the same manner as the first panel. Succeeding exterior wall.

panels are then erected and secured until (according to. the plans) all the panels to be connected to one fioor panelCF are in place. Then any interior partition panels 33?, which will be related to that floor panel, are erected and keyed to it and to the exterior wall panels. It is desirable to place between the flange of the stud of an exterior wall panel and the web of the stud of any interior wall panel connection thereto a plywood spacer strip. A ceiling panel CF is then placed in position after having fastened to the corners thereof saddle brackets 45. The saddle bracket 46 is shown as a double saddle bracket. If one corner of the ceiling panel CF is in alignment with a corner of the framework, a single saddle bracket is used instead of the double saddle bracket 18. The single saddle bracket is half the size of a double saddle bracket and is provided with only one set of slots for the entrance of key and taper pin connectors. A single saddle bracket is indicated generally at 41 in Figure l. The saddle brackets rest upon the connecting brackets 18 of the exterior wall panels EP. Key and taper pin connectors connect the brackets 58 to the saddle brackets 46, which in turn are keyed to the ceiling panels CF, as is generally indicated at Figure 10.

After all panels have been erected, the interior partition panels IP may then be straightened and nailed to the sub-floor by nails passing through the bearing plates 35?. Finally, batten strips 26 are nailed in the spacing formed at each exterior wall panel joint.

A building framework constructed in accordance with the foregoing description has steel studs or support members encased within the confines of a layer of insulation comprising wood fiber insulation board and dead-air spaces. This is of particular advantage in that rapid and relatively wide changes in the temperature of the steel supports will not take place as they are subjected to interior or room temperature, which does not undergo rapid, relatively wide change. Thus condensation is prevented, and corrosion of the steel minimized. Likewise, such a building framework is essentially fire-proof. Each panel comprising the framework has a series of horizontally disposed cross nailers, which define dead-air spaces of relatively small area therebetween. Thi eliminates draft within the wall, thereby checking air circulation and preventing the spread of fire.

As is illustrated in Figure 1, there can be applied to the outer surface or plywood covering 22 any desired exterior finish, such as brick 48 or wood siding '39. Any desirable building paper 50 is inserted between the finish and the plywood covering 22. The wood siding is nailed directly to the horizontal wood nailers l2. Likewise, the cleats or connectors for joining the brick finish to the building framework can be nailed directly to the wood cross nailers l2.

The interior of the building framework is adapted to receive (by nailing to the cross nailers 2) a base or gypsum board lath to which plaster or other interior finish may be applied. The base and interior finish thus applied will be spaced from the flanges of the steel studs Ill and H because the sides of the cross nailers l2 and SI project beyond said flanges. Any sweating or showing through of the steel studs in the base and plaster.

Although there is shown and described certainv specific embodiments of the invention, many The inven-. tion is not to be restricted except in so far as:

modifications thereof. are possible.

is necessitated by the prior art and by the spirit of the appended claims.

We claim:

1. A building unit adapted for connection with similar units to form a building frame, and comprising two steel channel-shaped studs, wood girts spanning said studs and fitted between the flanges thereof, and a layer of insulation secured to said girts on one side of said unit and consisting of on inner layer of wood fiber board and a plywood covering spaced by furring strips forming dead-air spaces therebetween, said furring strips completely extending around the border of said board.

2. A prefabricated exterior wall panel building unit of the character described comprising metal side framing members, wood girts extending between and secured to said members and adapted to have the inside finish of the building applied and fastened thereto, and a layer of insulation comprising a layer of wood fibre insulation board coextensive with the area defined by said members, furring strips extending around the border of said board, and a plywood covering having its side edges recessed from the outer edges of said furring strips to receive a batten strip therein when two of said units are placed in abutting relationship, all fastened to said wood girts and disposed on the outside of and secured to said unit so as to be interposed between the exterior of the building and said metal framing members whereby to maintain the metal framing members at substantially the tempera-f ture of the inside of the building to preclude condensation thereon and protect said metal framing members against corrosion.

3. A prefabricated exterior wall panel building unit of the character described comprising metal side framing members, and a layer of insulation comprising a layer of wood fibre insulation board coextensive with the area defined by said members, furring strips extending around the border of said board, and a plywood covering having its side edges recessed from the outer edges of said furring strips to receive a batten strip therein when two of said units are placed in abutting relationship, all disposed on the outside of and secured to said unit so as to be interposed between the exterior of the building and said metal framing members whereby to maintain the metal framing members at substantially the temperature of the inside of the building to preclude condensation thereon and protect said metal framing members against corrosion.

4. A prefabricated exterior wall panel adapted for connection with similar'units, comprising two channel-shaped vertically extending metallic studs positioned with flanges facing and forming the sides of said panel, a plurality of horizontal, spaced wood girts extending between said studs, said girts being spaced at close enough intervals to provide dead air spaces, the corners of said girts being notched to receive the flanges of said studs, nails passing through said flanges into said girts to secure them to said studs, a sheet of wood fibre insulation board coextensive with the area defined by said studs positioned on one side interior. finishwill be prevented because of the airspace between the steelstuds and the plaster..-

of said girts, furring strips positioned on said sheet and extending completely around the entire boarder thereof, and a plywood covering resting on said strips, said covering having its side edge recessed from the outervertical edges of said iurring strips whereby when two of said units are placed with the channels thereof in fiat abutting relationship a batten strip maybe inserted flush within the recesses and nailed to said furring strips, said covering, strips and sheet all being nailed directly to said girts.

ARTHUR W. RENHVIEL. ROY H. BRENT. 

